A critical review on energy use and savings in the cement industries

Madlool, N.A.; Saidur, R.; Hossain, M.S.; Rahim, N.A.

doi:10.1016/j.rser.2011.01.005

Cited by 542 publications

(239 citation statements)

References 52 publications

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“…In terms of a comprehensive literature review, CO 2 emissions and energy use at different sections of cement industry have been identified (Ali et al, 2011;Madlool et al, 2011). At the macro level, factors affecting CO 2 emissions in cement industry have been decomposed into energy factor effect, energy structure effect, energy intensity effect, cement production activity effect and clinker production activity effect (Kim and Worrell, 2002;Wang et al, 2013;Xu et al, 2012).…”

Section: Introductionmentioning

confidence: 99%

Modeling the dynamic mechanism between cement CO2 emissions and clinker quality to realize low-carbon cement

Cao

Shen

Zhao

et al. 2016

Resources, Conservation and Recycling

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a b s t r a c tTo devise low-carbon cement clinker product, in-depth knowledge about the variation mechanism of cement clinker CO 2 emissions is the prerequisite. The determinants of cement clinker CO 2 emissions in Chinese cement industry have been inquired by several researches recently. However, the impacts and abatement effect of clinker quality on cement clinker CO 2 emissions have not been identified yet. In technological sense, there lacks an integrated quantitative model that can elucidate the dynamic mechanism between cement clinker CO 2 emissions and clinker quality. To fill this gap, this paper devises a CO 2 emission accounting framework integrated with optimization model to explore the dynamic mechanism between cement clinker CO 2 emissions and clinker quality. Based on survey data of 2 typical cement clinker production lines in China, the accounting framework is validated with measured data. Through numerical simulation within this framework, a set of sensitivity analysis is conducted. The results indicate that if the target KH (lime saturation ratio) of both production lines climb from −5% to +5%, the process CO 2 emission factor will give rise to an increase of about 16.4 and 14.8 kg CO 2 /t clinker, respectively. With the same variation, the fuel CO 2 emission factors of two production lines will gain 17.2 and 13.7 kg CO 2 /t clinker, respectively. Obviously, controlled decrease of clinker quality can reduce CO 2 emission of clinker manufacturing. The results of sensitivity analysis are robust and highlight the remarkable role of clinker quality in both process and fuel emissions. Besides, the integrated framework can provide in-depth investigation into the dynamic mechanism between CO 2 emissions and the other determinants. Using this framework, cement plants or industry can develop optimal clinker quality standards on a quantitative basis to achieve low-carbon clinker.

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Section: Introductionmentioning

confidence: 99%

Modeling the dynamic mechanism between cement CO2 emissions and clinker quality to realize low-carbon cement

Cao

Shen

Zhao

et al. 2016

Resources, Conservation and Recycling

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“…The primary pieces of equipment used in cement production are electrical motors, pumps, compressors, transformers, furnaces, fans, blowers, conveyors, chillers, cooling towers, kiln, transportation systems, and lighting systems (Madlool et al, 2011). Clinker is produced by burning a mixture of materials in a cement kiln.…”

Section: Materials Flow In Cement Production Processmentioning

confidence: 99%

“…The primary calcination (60e65%) occurs in the pre-calciner chamber, which consumes approximately 40% of the coal used in the kiln. In the pre-heater and pre-calciner system, approximately 80e90% of the raw meal is calcined (Madlool et al, 2011) to produce CO 2 , which is discharged from the top of the cyclones. The pre-calcined meal then enters the kiln, and slides and tumbles down through increasingly hotter zones, where fuel is fired directly to attain temperatures of up to 1723.15 K. Then, a reaction takes place between calcium oxide and other elements.…”

Section: Mass Flows In Clinker Productionmentioning

confidence: 99%

Analysis of material flow and consumption in cement production process

Tianming

Shen

et al. 2016

Journal of Cleaner Production

115

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a b s t r a c tCement production, which is highly dependent on the availability of natural resources, will face severe resource constraints in the future. This is especially true for the cement industry in China. Thus, the industry is focusing on reducing the consumption of natural resources at both the manufacturing and operational stages. The aim of this article is to improve the management of resources used in the cement production process and mitigate their environmental effects. First, material flow routes for the cement manufacturing process are established, after which three mass balances are built during the three production stages using actual plant data received from an existing cement manufacturing facility. Finally, the material efficiency of the units and stages as well as the waste recycle rates during these stages is calculated. The results show that approximately 2.48 t, 4.69 t, and 3.41 t of materials are required to produce a ton of the product in raw material preparation, clinker production, and cement grinding stages, and their waste rates are 63.31%, 74.12%, and 78.89%, respectively. The recycling rate of wastes during clinker production is remarkably higher than those during other manufacturing stages, wherein waste gases are directly discharged into the atmosphere. The material efficiency values for a raw mill, pyro-processing tower, rotary kiln, clink cooler, and cement mill are determined to be 36.69%, 34.24%, 39.24%, 29.76%, and 25.88%, respectively, whereas the waste recycling rates for these units are found to be 16.33%, 81.98%, 100.00%, 99.53%, and 0.00% respectively. These results will provide researchers with knowledge regarding the effectiveness and efficient use of natural resources in the cement sector. These important findings can also be used to influence the development of national and industrial policies in relation to the goal of achieving sustainable development in the cement industry.Crown

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“…During the production process, only the kiln must keep running, while the operation time of the raw mill and cement mill can be shifted as needed. These two adjustable sub processes account for 60%-70% of the total electricity consumption in cement production [24]. A simplified process diagram of cement production in a large cement plant is shown in Figure 4.…”

Section: Cementmentioning

confidence: 99%

Integrated Power Management of Conventional Units and Industrial Loads in China’s Ancillary Services Scheduling

Yao

Sifuentes

et al. 2015

Energies

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Abstract:With the development of the smart grid in China, new opportunities for responsive industrial loads to participate in the provision of ancillary services (AS) will become accessible. This paper summarizes AS in China and analyzes the necessary characteristics and advantages of industrial users to provide AS according to their response mechanism. Cement manufacturing and aluminum smelter processes are selected as two representatives of responsive industrial loads. An agent-based model that includes generation, industrial user, and grid agents is proposed. Using two case studies, we analyze the integrated power management of conventional units and industrial loads in day-ahead and real-time AS scheduling based on real device parameters, price mechanisms and production data. The simulation results indicate that the participation of responsive industrial loads in the provision of AS, in China, can improve the coal consumption rate and the system-wide load factor as well as reduce the total system cost for the provision of AS significantly.

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A critical review on energy use and savings in the cement industries

Cited by 542 publications

References 52 publications

Modeling the dynamic mechanism between cement CO2 emissions and clinker quality to realize low-carbon cement

Modeling the dynamic mechanism between cement CO2 emissions and clinker quality to realize low-carbon cement

Analysis of material flow and consumption in cement production process

Integrated Power Management of Conventional Units and Industrial Loads in China’s Ancillary Services Scheduling

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